Method for multiple process parameter matching

ABSTRACT

A computer-implemented method for matching parameters of outputs generated by a first and second process. The first process generates a first output having a characteristic measurable by a first parameter, and the second process generates a second output having the characteristic measurable by a second parameter. A computer having a processing unit and memory is provided. The computer generates a first model of the first parameter for the first process and a second model of the second parameter for the second process. The computer generates a first simulated output of the first process using the first model. A correction, which is a function of the second model and which compensates for the effect of the second process on the second parameter, is applied to the first simulated output to obtain a corrected output. The second process is applied to the corrected output to generate with the computer thereby a third output matching the first parameter of the first output.

FIELD OF THE INVENTION

This invention relates to photolithography. More particularly, this invention relates to the changing of photolithographic processes in the fabrication of integrated circuit parts.

BACKGROUND OF THE INVENTION

Photolithography is one method used to produce integrated circuit parts for semiconductor chips. Photolithography consists of processing substrate wafers with stepper machines that have been loaded with photomasks. This processing fabricates hundreds of integrated circuit parts on each wafer. The microscopic detail of the circuits created on the wafers makes photolithography a very exacting manufacturing method. Just a small change in the setup of the equipment or in one of the operating variables can drastically alter the resulting wafers.

However, in the course of production, one may wish to change the process. For example, although a current process may be providing for yields with good critical dimension behavior, the depth of focus may be unacceptable. A new process, using a different illumination setup may be desired. Altering the illumination may improve the depth of focus. The alteration may, however, cause a decline in critical dimension behavior. Other behaviors may also be of concern, including those caused by the photoresist process, etch process, or mask process.

What is needed is a process matching method which would allow the photolithography process to be changed without introducing variances within the resulting wafer images. The wafer image from the new process should be the same as the initial wafer image. In such a system, the results of the primary process are matched to the results of a secondary process.

One useful tool for improving a wafer image is optical proximity effect correction ("OPC"). OPC is a misnomer since the term now encompasses not only optical proximity-effect correction, but also etch proximity effect correction and all other forms of corrections to proximity effects. In OPC, a correction is made to a photomask design to compensate for dimensional and positional inaccuracies resulting from optical or etch effects. It is well known that there are several ways to accomplish OPC. One way is by a rule-based system. In such a system, a pattern for a photomask is analyzed by a series of rules, which isolate and adjust the problematic edges. A wafer printed from the OPC-corrected pattern should result in a flat printed "critical dimension vs. environment" response based on proximity.

A model-based system is a second type of OPC. A model is a mathematical description of a system. In a photolithography system, a model can describe optical, optical through resist, or other system. Regardless of the type of system described, there are generally two types of models. A theoretical model relies on the pure science involved in the system. Often, a theoretical model will be used to describe optical systems. Otherwise an empirical model can be used. In an empirical model, copious measurements are compiled and are then used to generate a set of formulae describing the behavior of the system.

In OPC, first, a simulation is made by applying the photomask pattern to the model. The resulting value is a prediction on how the pattern will print on the wafer. The prediction is the intensity return value. If normalized to a scale of 1, an intensity return value of 0 indicates chrome and a value of 1 indicates quartz. After obtaining the resulting value, then the factor of change needed to compensate for the proximity effect is calculated. In general, a threshold is determined, which is the intensity that is required to print on the wafer. For positive tone resist, above threshold equals clear substrate, below threshold equals resist. Then the intensity return value from the simulation is subtracted from the threshold value to find the intensity difference. This difference is then used to find the physical offset necessary to correct the pattern. This OPC method is repeated at close intervals throughout the pattern, resulting in a corrected photomask pattern.

SUMMARY OF THE INVENTION

A computer-implemented method for matching parameters of outputs generated by a first and second process. The first process generates a first output having a characteristic measurable by a first parameter, and the second process generates a second output having the characteristic measurable by a second parameter. A computer having a processing unit and storage is provided. The computer generates a first model of the first parameter for the first process and a second model of the second parameter for the second process. The computer generates a first simulated output of the first process using the first model. A correction, which is a function of the second model and which compensates for the effect of the second process on the second parameter, is applied to the first simulated output to obtain a corrected output. The second process is applied to the corrected output to generate with the computer thereby a third output matching the first parameter of the first output.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart of two processes.

FIG. 2 is a flowchart showing a method of process matching.

FIG. 3 is an illustration of the matching of the wafer image after a process change by simulation and proximity effect correction.

FIG. 4 is a block diagram of a computer system which produces process matching.

DETAILED DESCRIPTION

In the following Detailed Description, reference is made to the accompanying drawings which form a part hereof and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice and to use the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present invention. The following Detailed Description is, therefore, not to be taken in a limiting sense and the scope of the invention is defined by the appended claims. In the figures, elements having the same number perform essentially the same functions.

The present invention permits a change in process while maintaining the same wafer image, thus allowing a migration from one process to another with wafer image continuity. Process matching is the method of achieving a desired output of a process based on the another process which achieves the desired output. For example, FIG. 1 is a flowchart showing two processes, process₋₋ 1 105 and process₋₋ 2 110. Process₋₋ 1 105 accepts input₋₋ 1 115 and generates output₋₋ 1 125. Similarly, process₋₋ 2 110 accepts input₋₋ 2 120 and generates output₋₋ 2 130. These processes can be symbolized with the notation:

    ______________________________________                                         OUTPUT.sub.-- 1 = PROCESS.sub.-- 1(INPUT.sub.-- 1)                             OUTPUT.sub.-- 2 = PROCESS.sub.-- 2(IUNPUT.sub.-- 2)                            ______________________________________                                    

A process's effectiveness can be gauged by the values of any of a number of parameters applied to the output produced for a given characteristic. In FIG. 1, process₋₋ 1's effectiveness can be gauged by parameters A₋₋ 1 135 and B₋₋ 1 145. Likewise, the effectiveness of process₋₋ 2 is measured by the parameters A₋₋ 2 140 and B₋₋ 2 150. In a situation where parameter A₋₋ 1 135 is satisfactorily achieved in output₋₋ 1 125 by process₋₋ 1 105, and where there is a second process (process₋₋ 2 110), which results in a desired level of parameter B₋₋ 2 150, but not A₋₋ 2 140 (assuming input₋₋ 1 115 and input₋₋ 2 120 are equal), one of the goals of the present invention is to modify the input to process₋₋ 2 110 so that output₋₋ 2 130 results in an A₋₋ 2 140 parameter as good as A₋₋ 1 135. The matching of these processes can be written as:

    ______________________________________                                         OUTPUT.sub.-- 1 = PROCESS.sub.-- 1(INPUT.sub.-- 1):                                                     A.sub.-- 1 = good                                                              B.sub.-- 1 = bad                                      OUTPUT.sub.-- 2 = PROCESS.sub.-- 2(INPUT.sub.-- 2):                                                     A.sub.-- 2 = bad                                                               B.sub.-- 2 = good                                     OUTPUT.sub.-- 2 = PROCESS.sub.-- MATCHING(INPUT.sub.-- 2):                                              A.sub.-- 2 ≈ A.sub.-- 1 =                                              good                                                                           B.sub.-- 2 = good                                     ______________________________________                                    

Although there are several situations in which process matching is useful, one exemplary use is in the field of semiconductor fabrication by photolithography. While building semiconductor wafers, a change in setup variables, such as a change in the illuminator, causes the wafer image produced from a photomask or reticle to vary. However, sometimes such a change will improve the value of one parameter while decreasing the value of another. The present invention allows a process to be introduced without causing a change in the wafer image with respect to a particular parameter. In addition to supporting a photolithographic process, other processes supported by the present invention include, but are not limited to the following: an ion projection process, an x-ray projection process and an e-beam projection process.

Two parameters of a wafer image which can be used to measured the effectiveness of the manufacturing process are critical dimension behavior and depth of focus. Process₋₋ 1 105 could be a set-up using on-axis illumination. The output₋₋ 1 125 of this process is the wafer image. This wafer image could have a good critical dimension behavior but a poor depth of focus (i.e., A₋₋ 1=good, B₋₋ 1=bad). However, the wafer image output resulting from the use of off-axis illumination (process₋₋ 2 110) might improve the depth of focus (i.e., B₋₋ 2=good) but not provide for quality critical dimension behavior (A₋₋ 2=bad). By using process₋₋ 2 110 instead of process₋₋ 1 105, the favorable A₋₋ 1 parameter 135 would be lost. The goal of process matching in this example is to transform input₋₋ 2 120 so that the behavior of process₋₋ 2 110 is good, i.e., so that the use of off-axis illumination improves the depth of focus (B₋₋ 2 150) without degrading the critical dimension behavior parameter (A₋₋ 2 140).

Process matching is accomplished through the unconventional uses of OPC and simulation. Traditionally, simulation is used upon input data, such as a photomask pattern, to predict how the pattern will print on the wafer based on a given model. Then OPC corrects the photomask pattern by adjusting the edges so that when the pattern is printed on the wafer, the proximity effect is mitigated. Symbolically, by using the SIM-subscript to denote "simulation", simulation is:

    ______________________________________                                         OUTPUT.sub.-- 1.sub.SIM = PROCESS.sub.-- 1.sub.SIM (INPUT.sub.-- 1).           ______________________________________                                    

At any point in the pattern, the offset value amounting to the physical offset can be calculated. OPC involves adjusting the pattern by the offset value so that the wafer image reflects the photomask pattern correctly. For example, suppose a simulated point ("X1") on an edge in the pattern has an intensity return of 0.30. If the threshold is 0.32, then the intensity difference is 0.02 (e.g., 0.32-0.30=0.02). If the contour shows that at point X1 there is 300 nanometers of slope per intensity value, then the physical offset value is 6 (e.g., 300×0.02=6). This indicates that although it is desired that the edge falls at X1, because of the offset, the edge is really falling at (X1-6). The offset value is 6 here and thus the OPC compensation is to move the original edge of the pattern up by 6.

FIG. 2 is a flow chart showing process matching applied to FIG. 1's process₋₋ 1 105 and process₋₋ 2 110. In FIG. 2, at step 210, a simulation model of process₋₋ 1 is applied to input₋₋ 1 115. The simulation produces output₋₋ _(SIM) 215 and indicates where the edge is actually printing. The simulated output can be a three-dimensional image for a given contour level. Instead of correcting the input data to obtain the desired output data, as is usually done in OPC, the output data is stored without correction. Then at step 220, instead of using the original pattern (i.e., input₋₋ 2 120) as input for process₋₋ 2 110, the method uses the output generated from the model of process₋₋ 2 with OPC (from step 220) resulting in output₋₋ 2 130. As an optional step, the simulated output₋₋ 2 225 can be generated for verification purposes. This output₋₋ 2 130 is the same as the output₋₋ 2 130 from FIG. 1, except both parameters A₋₋ 2 140 and B₋₋ 2 150 are good.

Another way to formulate this method of process matching is by:

    ______________________________________                                         OUTPUT.sub.-- 2 =                                                              PROCESS.sub.-- 2[PROCESS.sub.-- 2.sub.SIM [PROCESS.sub.-- 1.sub.SIM            (INPUT.sub.-- 1)].sup.-1 ];                                                    THEREFORE:                                                                               IF (PROCESS.sub.-- 2 ≈ PROCESS.sub.-- 2.sub.SIM)                     THEN (OUTPUT.sub.-- 2 ≈ PROCESS.sub.-- 1.sub.SIM (INPUT.su             b.-- 1)).                                                              ______________________________________                                    

FIG. 3 illustrates the use of this process matching in photolithography. Here, process₋₋ 1 105 uses mask pattern 305 to produce wafer image 310. Thus, compared to FIG. 1, mask pattern 305 is input₋₋ 1 115 and wafer image 310 is output₋₋ 1 125.

A model of process₋₋ 1 210 can be created. This model can be used to generate a simulated wafer image 315 from the mask pattern 305 at a given contour level. The contour level ranges from 0 (representing chrome) to 1 (representing quartz). Then, in order to reduce the amount of data and to ease later corrections, a simulation approximation 325 may be generated of simulated wafer image 315.

When a new process₋₋ 2 110 is introduced, models of process₋₋ 2 can be generated 220. The simulation approximation data 325 is used as input to an OPC correction (e.g., process₋₋ 2_(SIM) 330). The output from this step 335 is used as input to process₋₋ 2 110 to gain a new wafer image 340. This new wafer image 340 is equivalent to the original wafer image 310, but it has the desired parameters values found in wafer images produced by process₋₋ 1 105 as well as the desired parameter values found in wafer images produced by process₋₋ 2 110.

FIG. 4 shows a computer system 405 which can implement the process matching method previously described. In FIG. 4, computer system 405 includes a central processing unit 410 and memory 420. Memory 420 can be RAM, disk storage, CD-ROM storage, or other type of memory. Within memory 420, computer system 410 has access to its operating system 430 and user software 440. To implement the method of the present invention, user software 440 can include software from Precim Company along with user-modified scripts. Or, user software 440 can be user-developed software, or software from some other vendor. Computer system 410 accepts input from input devices 450. Wafer image 310 can also be generated by software, such as FAIM from Vector Technologies (Brookline, Mass.), DEPICT from Technology Modeling Associates, Inc. (Sunnyvale, Calif.), and SPLAT by the University of California (Berkeley, Calif.). User software 440 also includes software which generates models (theoretical or empirical).

Other embodiments of the present invention are possible. For example, in addition to photolithography masks, the present invention can be used with x-ray masks, stencil masks for ion projection lithography, or electron beam projection lithography masks. In addition to photolithography, the present invention's method can be used for other processes for which output can be evaluated based upon one or more types of parameters. 

We claim:
 1. A method for matching parameters of generated outputs of a first photolithographic process and a second photolithographic process, comprising the steps of:providing a first photolithographic process; generating a first output from the first photolithographic process having a characteristic measurable by a first parameter; providing a second photolithographic process; generating a second output from the second photolithographic process having a characteristic measurable by a second parameter; generating a first model of the first parameter for the first photolithographic process; generating a second model of the second parameter for the second photolithographic process; generating a first simulated output of the first photolithographic process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the correction is a function of the second model and wherein the correction compensates for the effect of the second photolithographic process on the second parameter; and applying the second photolithographic process to the corrected output thereby generating a third output matching the first parameter of the first output.
 2. The method according to claim 1, wherein the step of providing a first photolithographic process and the step of providing a second photolithographic process is applied to a mask.
 3. The method according to claim 1, wherein the step of generating a first output further comprises the step of generating a first output from the first photolithographic process having a characteristic measurable by a critical dimension of a wafer image.
 4. The method according to claim 1, wherein the step of generating a second output further comprises the step of generating a second output from the second photolithographic process having a characteristic measurable by a depth of focus of a wafer image.
 5. The method according to claim 1, further comprising the step of generating from the corrected output a second simulated output for verification.
 6. The method according to claim 1, wherein the step of generating the first simulated output further comprises the step of generating a three-dimensional image.
 7. The method according to claim 2, wherein the step of generating from the corrected output a second simulated output further comprises the step of generating three-dimensional image.
 8. The method according to claim 1, wherein the step of applying a correction further comprises the step of applying an optical proximity correction.
 9. The method according to claim 1, wherein the step of applying a correction further comprises the step of applying a topography effect correction.
 10. The method according to claim 1, wherein the step of generating a first simulated output further comprises generating a first simulated output for a specific contour level.
 11. The method according to claim 1, wherein the step of generating a first model further includes the step of generating a first empirical model.
 12. The method according to claim 1, wherein the step of generating a second model further includes the step of generating a second empirical model.
 13. The method according to claim 1, wherein the step generating a first output includes the step of generating a wafer image.
 14. A method for matching parameters of generated outputs of a first ion projection process and a second ion projection process, comprising the steps of:providing a first ion projection process; generating a first output from the first ion projection process having a characteristic measurable by a first parameter; providing a second ion projection process; generating a second output from the second ion projection process having a characteristic measurable by a second parameter; generating a first model of the first parameter for the first ion projection process; generating a second model of the second parameter for the second ion projection process; generating a first simulated output of the first ion projection process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the correction is a function of the second model and wherein the correction compensates for the effect of the second ion projection process on the second parameter; and applying the second ion projection process to the corrected output thereby generating a third output matching the first parameter of the first output.
 15. A method for matching parameters of generated outputs of a first x-ray projection process and a second x-ray projection process, comprising the steps of:providing a first x-ray projection process; generating a first output from the first x-ray projection process having a characteristic measurable by a first parameter; providing a second x-ray projection process; generating a second output from the second x-ray projection process having a characteristic measurable by a second parameter; generating a first model of the first parameter for the first x-ray projection process; generating a second model of the second parameter for the second x-ray projection process; generating a first simulated output of the first x-ray projection process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the correction is a function of the second model and wherein the correction compensates for the effect of the second x-ray projection process on the second parameter; and applying the second x-ray projection process to the corrected output thereby generating a third output matching the first parameter of the first output.
 16. A method for matching parameters of generated outputs of a first e-beam projection process and a second e-beam projection process, comprising the steps of:providing a first e-beam projection process; generating a first output from the first e-beam projection process having a characteristic measurable by a first parameter; providing a second e-beam projection process; generating a second output from the second e-beam projection process having a characteristic measurable by a second parameter; generating a first model of the first parameter for the first e-beam projection process; generating a second model of the second parameter for the second e-beam projection process; generating a first simulated output of the first e-beam projection process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the correction is a function of the second model and wherein the correction compensates for the effect of the second e-beam projection process on the second parameter; and applying the second e-beam projection process to the corrected output thereby generating a third output matching the first parameter of the first output.
 17. A computer-implemented method for matching parameters of generated outputs of a first and second photolithographic process, comprising the steps of:providing a first photolithographic process; generating a wafer image from the first photolithographic process having a characteristic measurable by a first parameter; selecting a second photolithographic process; generating a wafer image from the second photolithographic process having a characteristic measurable by a second parameter; generating a first model of the first parameter for the first process; generating a second model of the second parameter for the second process; generating a first simulated output of the first process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the correction is a finction of the second model and wherein the correction compensates for the effect of the second process on the second parameter; and applying the second process to the corrected output thereby a third output matching the first parameter of the first output.
 18. The method according to claim 17, further comprising the step of generating from the corrected output a second simulated output for verification.
 19. The method according to claim 17, wherein the step of generating the first simulated output further comprises the step of generating a three-dimensional image.
 20. The method according to claim 18, wherein the step of generating from the corrected output a second simulated output further comprises the step of generating three-dimensional image.
 21. The method according to claim 17, wherein the step of applying a correction further comprises the step of applying an optical proximity correction.
 22. The method according to claim 17, wherein the step of applying a correction further comprises the step of applying a topography effect correction.
 23. The method according to claim 17, wherein the step of generating a first simulated output firther comprises generating a first simulated output for a specific contour level.
 24. The method according to claim 17, wherein the step of generating a first model further includes the step of generating a first empirical model.
 25. The method according to claim 17, wherein the step of generating a second model further includes the step of generating a second empirical model.
 26. A method of changing a process among a plurality of processes applied to a mask for fabricating semiconductor devices, comprising the steps of:generating a first output from a first process having a characteristic measurable by a first parameter; generating a second output from a second process having a characteristic measurable by a second parameter; generating a first model of the first parameter; generating a second model of the second parameter; generating a first simulated output of the first process using the first model; applying a correction to the first simulated output to obtain a corrected output, wherein the output is a function of the second model and wherein the correction compensates for the effect of the second process on the second parameter; and applying the second process to the corrected output thereby generating a third output, wherein the third output is reflective of a change in a process among the plurality of processes, and wherein a wafer image is unchanged with respect to a desired parameter.
 27. The method according to claim 26, wherein the step of providing a first process and the step of providing a second process is applied to a mask.
 28. The method according to claim 26, wherein the step of generating a first output further comprises the step of generating a first output from a first process having a characteristic measurable by a critical dimension of the wafer image.
 29. The method according to claim 26, wherein the step of generating a second output further comprises the step of generating a second output from a second process having a characteristic measurable by a depth of focus of the wafer image. 